Carpet Yarn Denier Differential Improvements

ABSTRACT

Different combining techniques are employed for directing multiple denier yarns to be tufted adjacently in a carpet by a tufting machine. Different aesthetic appearances be achieved which provide for many new design opportunities in the marketplace.

FIELD OF THE INVENTION

The present invention relates to improvements for making and using joined yarn with carpet.

BACKGROUND OF THE INVENTION

Creel patents, such as U.S. Pat. Nos. 5,531,392 and 5,613,613 have been used to provide some striated patterned carpets, however, utilizing such technology is extremely unpractical for solution dyed yarns. In order to change the look of a finished product, one would likely need to completely restring the creel which would be an extremely cumbersome practice not likely to be performed by carpet manufacturers. In fact, when the applicant owned those two patents, he never attempted to use solution dyed yarn for such a practice. All carpets produced using that technology were done using piece dyable and/or skein dyable yarn to then be dyed after the tufting of the carpet to desired patterns. Depending on the particular dyes utilized, different carpet colorations could be provided. At least some colorations could be determined after the tufting process. However, one disagreeable aspect to these type yarns is that if a stain is attempted to be removed, such as by bleaching and/or use of other harsh chemical procedures, permanent discoloration of the carpet can occur.

Remember, a disadvantage of dyable yarn whether it be piece dyed or it be space dyed or skein dyed, is that should the carpet be then subjected to a stain or a bleach, an imperfection is then provided in the affected area. Solution dyed yarn is much less susceptible to bleaches or stains or ultraviolet light or ozone.

Additionally, although two (or more) yarns fed to a single needle, there was no effort made to intentionally vary the denier and/or orientation of yarns fed to a single needle and/or from a common beam.

Improved methods of twisting yarns together and then using twisted yarns with tufting machines needles so that multiple yarns can pass through a single needle are believed to be desirable in the carpet industry.

Improved methods of providing different yarns, and even different denier yarns to a single needle are believed to be desirable over prior art technology.

SUMMARY OF THE INVENTION

It is an object of many embodiments of the present invention to provide an improved method of manufacturing carpet.

It is another object of many embodiments of the present invention to provide an improved carpet construction when at least two yarns are directed through a single needle having a denier differential between the two yarns.

It is another object of at least some embodiments of the present invention to provide an improved carpet construction wherein a denier differential (i.e., by way of example, one yarn having a high denier as defined as 1000 or more, and a second yarn having a low denier as defined as less than 1000. Some low denier yarns may be as low as 15, if not lower (like some small gauge monofilaments). Other denier differentials could be at least a difference of 50, 100, 150, 200, 250, 300, etc. (and/or be expressed as a fraction ⅘, ¾, ⅔, etc., or as a percentage 120%, 125%, 150%, etc.).

For at least still other embodiments, a denier differential could exist between at least two yarns in the carpet design whereby a first yarn has a first denier, and a second yarn has a second denier lower than the first twist per inch. The differential or denier differential gives rise to at least one functional and aesthetic characteristic. In fact, at least two different denier, if not three or more, could be directed from a single beam to a single needle.

It is another object of at least some embodiments to utilize unbalanced tension on a twister with denier differential so as to create different effects of yarn when it is run through needles to tuft carpet.

While twisting is a possibility to combine yarns of differing deniers, some of the yarns could additionally (or alternatively) be cabled, piggy backed, provided from one or more beam supply, warped together and/or otherwise be joined, possibly at a single needle, for a variety of effects.

Accordingly, in accordance with a presently preferred embodiment of the present invention, a number of twisting or joining methods and techniques can be employed for use in making twisted and/or joined yarns for use with carpets. U.S. patent application Ser. No. 15/430,680 is hereby incorporated by reference in its entirety.

A denier differential carpet design can be manufactured. Specifically, at least first and second yarns (if not attached and/or others) may be directed through a single eye of a needle in manufacturing carpet and/or in adjacent needles, possibly from one or more beams.

It is an object of some presently preferred embodiments of the present invention to provide improved solution dyed carpet configuration.

It is another object of many embodiments of the present invention to provide an improved carpet having solution dyed yarns predominantly throughout, having at least one tuft row with an intentionally provided striated appearance of at least some random direction.

It is another object of many embodiments of the present invention to provide a predominantly solution dyed carpet possibly having a unique and randomized yarn arrangement. These can be distinguished from piece, skein, or space dyed carpets. Harsh chemical treatment can be applied to solution dyed carpet without removing the underlying coloration of the yarns, while harsh chemicals tend to bleach out piece, skein, or space dyed carpets thereby providing discoloration.

Accordingly, according to a presently preferred embodiment of the present invention an improved carpet configuration is provided in which at least first and second yarns of differing deniers may be provided together in a non-uniform, or random arrangement together through a single needle such as could be performed with a twister, a warper, or other methodology so that when the yarns are tufted through a single needle of a yarn, they provide one of a plurality of possible striated looks across the surface of the carpet due to a non-uniform twist pattern, joining or combining, particularly when having a denier differential of at least 50, 100, 150, 200, 250, 300, etc. between first and second yarns. Denier differentially could also be one yarn having a denier of 120% of the other yarn(s) (125%, 150%, 200%, etc. are also possibilities).

Non-uniform twisting can be performed in many ways whether it is a core cabling technique, a winding technique using a winder, a twisting technique using a twister, or other techniques so as to preferably be able to provide denier differential yarns together in a non-uniform manner whether that be random, or even a reversing manner where it is a right hand twist followed by a left hand twist such as over a predetermined length whether over less than 20 feet or less than 10 feet with a twist pattern preferably less than about one twist per foot or maybe a higher twist such as one twist per inch but more likely one twist per 18 to 24 inches is more likely, or even less. Randomization (i.e., changing orientations of the three or more yarns) either with or without varying twist rate can be provided in many embodiments as well.

For some embodiments, the direction of twist preferably changes such as going from right hand twist to left hand twist approximately within every twenty feet if not every ten feet, although the rate of twist might be larger or smaller over specific segments. In addition to first and second yarns, there may also be preferably third and fourth yarns, some of which may also provide denier differential relation to the first and second yarns, which may provide a striation pattern parallel to the first and second yarns with a tuft row which could be similar or dissimilar in twist construction through a second needle. A fifth yarn could be provided through a third needle to provide a uniform tuft row parallel to tuft rows created by the first and second needles.

Additionally, in addition to the appearance of randomized patterns or orientation of at least two yarns along a tuft row, the yarns could also be tufted to multiple elevations which give yarn an additional effect as a result of the striation patterns.

As the yarns of the carpet are solution dyed as opposed to piece dyed or skein dyed, these yarns are virtually impervious to stain and bleach. Accordingly, in the event they are spilled upon with aggressive solvents and/or stains and/or bleach, they are extremely resistant to stain as opposed to the piece dyed or stain dyed goods which are quickly blemished.

In addition to the carpet construction design, the method of producing the carpet is believed to be novel, such as by providing denier differential yarns from a common beam, i.e., a single rotating member rotating about a single axis with multiple yarns (of at least two deniers) wound thereabout.

Accordingly, in accordance with a presently preferred embodiment of the present invention, a denier differential carpet design can be manufactured as provided for some embodiments. Specifically, at least first and second yarns with a denier differential may be directed through a single eye of a needle when manufacturing carpet and/or in adjacent needles. These two yarns may be running side by side, if not parallel, may be twisted, may be cabled, may be core cabled, or other methods of providing yarns through a single or multiple needles in such embodiments. The first yarns may, or may not, be a high denier yarn as defined as having a denier of at least 1000. The second yarn may, or may not, be a low denier yarn comprised of denier less than 1000. By combining these two yarns together, particularly in a single beam, an unexpected result of having different denier possibly together or adjacent, if not directed to a single needle can be provided. The first and second yarns (if not third or more, etc.) are likely to have the same length of yarn on a beam, if provided from a common beam. Different weights are likely provided by differing denier differential yarns and may provide a more economical carpet product with higher performance than would otherwise be expected. Furthermore, a different aesthetic appearance is provided than if all the same denier yarns are used.

When utilizing multiple yarns 14-18 of at least two deniers through a single needle 12, one may do this in multiple fashions whether it be through parallel feeding, twisting, cabling, core-cabling such as shown in co-pending application Ser. No. 14/160,123, incorporated herein by reference, or other technologies whereby multiple yarns would be simultaneously fed through a single eye 20 of a needle 12. All these type configurations of the present construction are believed to provide an aesthetic look which differs from prior art configurations. Specifically, the present embodiments preferably use pre-dyed yarns such as solution or skein dyed yarns as first and second yarns 16,18.

First and second yarns 16,18 are preferably dyed before tufting, such as solution dyed yarns or skein dyed yarns. Furthermore, one of the first and second yarns may have no twist at all for at least some embodiments.

Other denier differential carpet designs may have at least four 100 denier difference between first and second (or third, etc.) yarns.

While utilizing multiple yarns to a single needle as a presently preferred embodiment, it may be possible for other embodiments to utilize a single yarn end through each needle with adjacent needles providing the first yarn and second yarn respectively for at least some embodiments which can still achieve the increased durability of something similar to a high denier (or higher denier) yarn construction while providing a lower weight and thus easier to install product and also a more economical product for the carpet manufacturer with yet a different aesthetic appearance than has been achieved with prior art constructions.

Whereas a 50-50 ratio of high denier and low denier yarns was utilized for a test embodiment, the expected characteristics would be a durability factor also referred to as a wear index or carpet performance rating of half way between that of the high denier yarn and the low denier yarn like the carpet density. This was not the case. In fact, the durability factor has been found to be at least 10% higher than that of the calculated linear amount thereby providing an unexpected result over prior art constructions.

Additionally, when utilizing a twister such as the Volkmann twisters and others, uniform tension is normally provided by twisted denier differential yarns. The applicant has developed a system of purposefully providing unbalanced tensions between two yarns being fed to a twister so as to create additional effects in the end carpet. A tweed look can be provided. This may be particularly noticeable with denier differential yarns. A tension can be provided on one yarn tighter than another when being twisted either for their entire length or switched to then be oppositely applied, such as with a processor, or otherwise to create a very different looking tweeded look. Other effects may also be provided as would be understood by those of ordinary skill in the art in practice. A first twisted pair or trio can be combined with another single yarn or pair as described herein or otherwise to pass through a single needle eye together for similar or dissimilar effects particularly when combined with differential denier yarns.

Furthermore, on a twister, the rate of twist can be extremely reduced in an attempt to provide more noticeable striation.

On a twister, the applicant has developed a way for at least some embodiments utilizing a single pass through the twister to ply together up to, if not at least three yarns. The applicant does not know of any successful efforts to utilize twisters such as the Volkmann twister technology for which two yarns are directed to the twister. The applicant has also developed a way to run more than one yarn from each of the two stations to the twister which is believed to have never been done in the prior art.

Additionally, at least one other improvement for use with yarns in carpet is the ability to use a warper to combine at least two ends together. This is a particularly attractive option as the warper can be run at a speed of roughly ten times that of a twister and therefore be utilized to twist yarns to provide a desired twist rate.

Additionally, while the ability to feed one yarn through the cone of another yarn is covered by U.S. patent application Ser. No. 14/160,123, the applicant has first developed a way of rotating one of those yarns about the other during feeding to increase the rate of twist. This feature is also believed to be novel.

A warper or other device can be used to twist at random twist rates for at least some embodiments to provide “striated” patterns. In fact, a warper or other device can wind multiple yarns on a single beam having different deniers. Higher denier yarns would likely have a higher weight than lower denier yarns as they would preferably have the same length on a beam.

BRIEF DESCRIPTION OF THE DRAWINGS

The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings in which:

FIG. 1 is a perspective view of a portion of a tufting machine tufting at least first and second yarns through a backing;

FIG. 2 shows a top plan view of a portion of a carpet design in accordance with a presently preferred embodiment of the present invention;

FIG. 3 is a schematic view of a modified twister for performing at least some embodiments of the present invention;

FIG. 4 is a schematic view of a warper performing at least some embodiments of the present invention;

FIG. 5 is a schematic view of a warper performing at least one embodiment of the present invention;

FIG. 6 shows a side plan view of a single needle puncturing through a backing to provide carpet;

FIG. 7 shows a top perspective view of the presently preferred embodiment of the present invention;

FIG. 8 shows a cross sectional view of a portion of carpet tufted in accordance with the methods of construction shown in FIG. 6 and FIG. 7;

FIG. 9 shows three yarns being displayed at the front as opposed to just two;

FIG. 10 is a photograph showing the striated effect of the presently preferred embodiment of the present invention;

FIG. 11 is a cross sectional view of the yarns shown in FIG. 6 at a first position along a length of yarn;

FIG. 12 is a cross sectional view of the yarns shown in FIG. 6 at a second position along a length of yarn; and

FIG. 13 is a portion of the perspective view shown in FIG. 1 with another arrangement of first, second and at least third, if not fourth and fifth yarns being directed through the eye of the needle.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows a presently preferred embodiment of the present invention of a tufting machine 10 with an exemplary first needle 12 which will have at least one if not a plurality of yarns illustrated as first yarn 14, second yarn 16, and/or third yarn 18, fourth yarn 15 and fifth yarn 17 directed through an eye 20 of a needle 12 for at least some embodiments of at least two differing deniers. More yarns than three can be run with some embodiments through a single needle 12. Other embodiments may have only a single yarn such as first yarn 14, second yarn 16, or third yarn 18 directed therethrough as will be explained in further detail below. First yarn 14 is illustrated as having a higher denier than second yarn 16, such as at least 50 and/or at least ⅕ or ¼ different (i.e. 120% or 125% of the value of). First or second yarn 14,16 may have no twist, or virtually no twist, for at least some embodiments. Third yarn 18, if utilized, could be a high, low denier yarn style and/or possibly different denier than first or second yarns 14,16. Some of the same deniers could be employed with any of first through fifth yarns 14,16,18,15,17. Four or more yarns 14,16,18 of at least one denier differential could be used with other embodiments.

While tufting with tufting machine 10, first and second yarns 14,16 can be tufted in a single location with a single needle 12 as shown in FIGS. 1 (including yarn 18) and 2. It is also possible that a single yarn illustrated as first yarn 14, second yarn 16, and/or third yarn 18 (or more, such as fourth or fifth yarn 15,17) can be tufted side by side and is also shown in FIG. 2 through adjacent needles 12,34 as would be understood by those of ordinary skill in the art through backing 22 in order to create a design.

First yarn 14 is shown as a high denier yarn as having a denier of at least 1000 in one embodiment of component filaments 38. Second yarn 16 is shown as a low denier yarn as one having less than 1000. Third yarn 18 could have high, low (and/or higher or lower denier). Fourth yarn 15, etc., could have high, low (and/or higher or lower) denier. Other embodiments may have other denier differentials. Furthermore, for at least some embodiments, first yarn 14 has a higher denier than second yarn 16 such as at least about by ⅕, ¼ or ⅓ more than the second yarn 16 if not a fixed amount such as 50 more. For some embodiments, this could mean first yarn 14 could have a denier of 1300 and the second yarn 16 could have a denier of 1250. In other embodiments the first yarn 14 could have a denier of 2000 and the second yarn 16 could have a denier of 1250. Denier could range from less than 10 to roughly 7000 for various yarns. Additionally, second yarn 16 (or any of the other yarns 14,18) may not be heat set for some embodiments. For at least some embodiments, it is desirable for no-twist yarns to not be heat set. On the other hand, high twist yarns could be heat set. A combination of higher denier yarns combined with lower denier yarns has been found to provide better performing carpet than would be expected, while still being effective. Wear testing, such as performed under ASTM D 5252, ASTM D 5417, D 6119 Foot Traffic or other testing is believed to exhibit better performing carpets than would be expected.

When utilizing multiple yarns 14-18 through a single needle 12, one may do this in multiple fashions whether it be parallel feeding, piggy backing, twisting, cabling, core-cabling such as shown in co-pending application Ser. No. 14/160,123, incorporated herein by reference, or other technologies whereby multiple yarns would be simultaneously fed through a single eye 20 of a needle 12. All these type configurations of the present construction are believed to provide an aesthetic look which differs from prior art configurations. Specifically, the present embodiments preferably use pre-dyed yarns such as solution dyed yarns as first and second yarns 16,18.

It may be possible that one of the first, second and third yarns 14,16,18 has a higher denier than the other two or that when tufting two or more yarns such as 14,18 a first yarn 14 may have a higher denier than second yarn 16, etc.

The applicant has found that a denier differential of at least about 50, 100, 150, 250, 300, if not more, may give rise to a perceivable aesthetic and/or functional difference. Another way to describe the denier differential for some embodiments is that the first yarn 14 denier is 120%, 125%, 150% or even 200% or more of the denier of the second yarn 16.

Additionally, the applicant has discovered that a high denier product such as of about 1000 or more can be relatively easily distinguished from a lower denier such as one of less than 1000. In such a case, the denier differential may be as low as 50 or less than 20% for at least some embodiments, but still give rise to a difference than not only aesthetics but also into the performance of the tufted carpet as shown on the figures.

It should also be noted that the first and second yarns 14,16 could be selected as having the same or similar density with a different denier and still provide a twist differential.

Accordingly, applicant believes that denier differential is desirable in many embodiments.

In a similar manner, FIG. 1 could also show first, second, third yarns 14,16,18 and/or fourth and fifth yarns 15,17 as being of different deniers.

While two yarns have been routinely directed through a single needle, whether twisted or joined through the process of the Creel patents of U.S. Pat. Nos. 5,531,392 and 5,613,613, adding the third 18, fourth 15 or fifth yarns 17 is not a normal procedure to proceed through a single eye 20 of a needle 12. For a tenth gauge machine total denier may be to about 7000 of all of the yarns 14,16,18,15,17 without changing needles and/or gauge for many embodiments. Usually the total denier may be less than 3500 for at least some embodiments.

The applicant has discovered that first and second yarns 14,16 can be twisted, cabled, or otherwise joined meaning fed or combined together, whether as a twisted pair with one of a predetermined twist rate along the entire length, a changing twist rate, and/or a random twist rate, or as joined yarns as could be combined in a similar or dissimilar manner as the Creel type patents of U.S. Pat. Nos. 5,531,392 and 5,613,613. In applicant's preferred embodiments, the yarns 14,16,18,15,17 are not secured to one another before proceeding through the eye 20 of the needle 12. Instead, it may be that first and second yarns 14,16 are twisted, cabled, and/or otherwise run together and then joined with third yarn 18, but are preferably directed from a common beam to an eye of the needle Not only can colors of the various yarns 14,16,18,15,17 be different, but the deniers 14,16,18,15,17 utilized may assist to provide aesthetic and/or other features not present in the marketplace to date.

Twisters can be utilized to provide the yarns directed to the group of yarns 14,16,18 and possibly including either of 15,17 as they are then could be wound about cones, beams or other structures for feeding to the eye 20 of a needle 12. Twisters traditionally are being used by the applicant and rated at about 75 yards per minute. Cabling techniques could also be utilized as could warpers, creels, beams and/or other supplies employed to direct the various yarns 14,16,18,15,17 as desired to a single eye 20 of a needle 12 to create various effects with at least two different deniers when tufted to become carpet as understood by those in the art.

Twisters can be utilized to twist the yarns and/or other methods of providing the twisted yarn could also be provided, such as warpers, creels, beams, cabling methodology and/or other techniques.

Additionally, when twisting or otherwise joining yarns, which is shown in a schematic in FIG. 3, unbalanced tension can be provided to the twister 100 (or other joining equipment such as warpers, beams, creels, cabling equipment, etc.) such as with tension wheels 102,104 from supplies 106,108 so that twisted yarn 110 has a different effect than the traditional twisting of twisting yarns under common tension. By providing an unbalanced tension, quite a different look can be obtained as has been obtained with prior art constructions. Furthermore, the amount of tension applied by the tension devices 102,104 can be changed for still further effects of the yarn 110 is created. The time of tension could also be changed (the entire yarn 110 need not be provided under a uniform set of tensions by tension devices 102,104). Opposite tensions could be applied and/or varying tensions could be applied over various intervals.

FIG. 4 shows a warper 200 being used in a way not done in the past. Specifically, multiple yarns can be fed from individual cones such as first cone 202 and second cone 204 and then twisted and warped to provide beam 206. No one is believed to have done this in the past.

Additionally, in the context of combining yarns together with twist, what is known with a prior application of the applicant is to run a second yarn supply 204 through a first yarn supply 202 (as explained by the applicant in a copending patent application). However, no one has ever rotated the first yarn supply 202 at the first yarn supply while running a second yarn supply 208 through the first yarn supply 202 such as by using at least one of first and second gears 210,212, the first gear being run by a motor 214 or otherwise so that the twist rate of twisted yarns such as at location 216 is greater than it otherwise would have been without the use of the rotation of the first yarn supply 206. There are certainly other ways that also could be employed to provide a desired rate of twist between at least two if not more than two yarns as well as about one more yarns.

While warper 300 is being shown as the instrument of choice, this could certainly be done with a twister or other cabling or joining equipment. Furthermore, although one fan 306 is shown, it would also be understood that more than one fan 306 and others could be utilized. Furthermore, selectively changing the speed of the fan or the direction of air flow against the yarns 308,310 during the joining process.

FIG. 6 shows a single needle 412 making a penetration 414 through a backing 416 to construct the carpet 410 of FIG. 7 of a presently preferred embodiment of the present invention.

The yarns proceeding through needle 412, which is shown beside needle 418, could be one of a set of needles as driven by a tufting machine 420 as understood by those of ordinary skill in the art to manufacture carpet 410. The needle 412 is provided with first, second and third yarns 422,424,426 which are solution dyed yarns as opposed to skein, space or piece dyed yarns. Accordingly, these yarns are manufactured to a specific color. The applicant is unaware of any other party utilizing a combination of solution dyed yarns 422,424,426 in a multiple manner through a single needle 12 when manufacturing carpet 10.

When tufting, tufting machines operate by directing backing 416 in a linear direction such as direction 428 shown in FIG. 7. Accordingly, the first needle 412 is shown providing row 430 of tufts which could contain the three yarns 422-426 as shown in the Figure. FIG. 9 shows this better with 422,424 and 426 proceeding from a single penetration such as first penetration 432 shown in FIG. 8. Depending upon the relative placement or orientation of the yarns 422-426 as they are directed by the needle 412 through the backing 416, one or two of the yarns 422-426 will likely be more prevalent as viewed from above an upper surface 434 after tufting. A third one of the yarns 422-426 if not a second one as well, is likely to be less prevalent once the carpet is tufted and viewed from above. Remember, the yarns 422-426 are preferably not physically joined together at intervals prior to directing through the needle 412. The yarns 422-426 will thus be restrained together at the penetrations 432 as they proceed through the backing 416, but are not otherwise connected together. They are joined together meaning that they proceed through a common penetration 432, but not connected together along lengths of the yarns 422-426 independent of the penetrations 432.

There are various ways to loosely twist yarn in the marketplace. Applicant has copending application Ser. No. 14/160,123 filed Jan. 21, 2014 incorporated herein by reference in its entirety. Twisting can intentionally reverse direction over a length of yarn using various techniques. Furthermore, randomization may also result in an appearance of reversing direction of twist over a length. Randomization may include re-orienting which occurs in yarn bundles 74 having at least three yarns A,B,C with at least one of the yarns changing relative positions relative to the others over a length. See also 62/217,251 filed Sep. 11, 2015, 62/168,001 filed May 29, 2015, and Ser. No. 14/617,054 filed Feb. 9, 2015, and/or 62/217,232 filed Sep. 11, 2015, all of which are incorporated by reference herein in their entirety.

FIGS. 11 and 12 are also useful to show relative yarn placement of the yarns. Assuming that the upper axis 472 would be a top most point of the bundle 474 when tufted, one will see that yarn A is more predominant in both FIGS. 11 and 12. C may not be visible at all in FIG. 11 as it is below A and B. Part of B and/or C may, or may not, be visible with relationship to FIG. 12 and certainly won't be as predominantly displayed as A due to their relative orientation below A. As the yarns A,B,C move relative to one another through the various processes as described herein and in the references incorporated by reference and others, on can see that a random or “striated” look can be created as can be seen from FIG. 10, the photograph. One half of a twist (or one yarn moving from toward the top 470 to toward a bottom (opposite 70)) over a few feet could still provide a noticeable striated pattern when tufted with differing deniers, the striated pattern may be more prominent.

For some embodiments, the yarns 422-426 could be twisted, cabled, warped, or otherwise joined together such as up to one twist for every inch which would be tight for many applications but more likely one twist for every 12 inches or one twist for every 24 inches or even looser twists as could occur through the various twisting or randomization methods. One half twist over every 12 inches or 24 or even 48 inches, particularly if random in nature over that distance could still create a “striated” look. It is further anticipated that random twists or even reverse twisting such as twisting to the right, which is one twist for every 24 inches, or twisting left, which is one twist for every 24 inches, preferably without pre-knotting, in between changing twist directions could be accomplished through various methodologies. It is anticipated that a first twist direction could occur for up to 20 feet or more if not once every ten feet for those embodiments (and then switch). Random twists can be imparted from various techniques as well as predetermined changes in twists for various embodiments.

Although twist is certainly discussed as a means to quantify how the yarns are bundled relative to one another, randomization relates to the relative change in position and for many embodiments, the relative position of the yarns is likely to change over a predetermined length, such as one foot, it is likely that at least one of the yarns will have moved at least 30 degrees relative to the other (like the approximately 60 degrees yarn A is shown moved from FIGS. 11 to 12 or the approximately 90 degrees for yarn B, or the approximate 180 degrees for yarn C). It may be that the length this occurs may be more like two to four feet (approximately) for still other embodiments or other lengths of yarn bundles 474.

More likely, warpers may be used to warp multiple yarns together onto a single cone while blowing a fan onto the yarns so that as the yarns are fed onto the cone, the relative positions change, and then tend to reverse, so that over a 100 foot length there may be relatively no net twist, but in any individual segment of 10 feet, there is likely to be some variation as to the relative orientation of the yarns relative to one another.

Furthermore, for re-orientation, which could occur with more than two yarns A,B,C, it is anticipated that the relative placement of the yarns A,B,C, may change over a set length for at least some embodiments, such as, on average, within a length of 50 or 100 feet, or even within 1000 feet. This means that there is not necessarily a twist, but the relative placement of the yarns relative to one another changes (see the difference between FIGS. 11 and 12 where B is to the right of A FIG. 11, but to the left of A in FIG. 12. Additionally, for quantification purposes, it can be expressly claimed, for at least some embodiments, that the relative placement of yarns relative to one another (orientation) changes at least once as described in this paragraph every 200 feet, if not every hundred feet, if not every fifty feet (or even more often like every 40,30,20 or possibly even every 10 feet for some embodiments), at least on average for a length of at least five hundred feet.

For more quantification for at least some embodiments, the angular relationship of at least one yarn can change over a length relative to another. For instance, yarn A moves at least 30 degrees between FIGS. 11 and 12 relative to top 470 as discussed above. Accordingly, it can be claimed, for at least some embodiments, that a first yarn A (or 22) move at least 30 degrees (or at least 30 degrees, or possibly no more than 30 degrees) relative to bundle 472 in a 5 foot length, if not over a 10 foot length (or 20, or 50 foot length, etc. for various embodiments), and/or as an average of every 10 feet over a one hundred foot length, etc. Yarn B moves 180 degrees over a similar length (or at least 180 degrees, or possibly no more than 180 degrees), while yarn C moves about 90 degrees (or at least 90 degrees, or possibly no more than 90 degrees) over a similar length.

The lengths as expressed herein could relate to either the yarns bundle 474 as it is fed to the needle 412 and/or the length of any particular row, such as first row 30, as expressed quantitatively for claiming purposes.

As can be seen with reference to FIG. 9, there are preferably no gaps where there are no yarns in carpet 410. Although first, second and third yarns 422,424,426 are illustrated in the first row 430, in the second row there may be no variation of twist or there could be different variations of either a single yarn or multiple yarns tufted in the adjacent rows such as the rows between rows 430,440 and/or 442. The yarns 422-426 are also preferably not fused together or mechanically joined together along a length prior to the needle 412 (although are joined to the carpet 10 by tufting through the backing, applying latex and/or other processing step). Furthermore, carpet can certainly be cut into tiles for at least some embodiments.

In addition to first and second yarns 422,424 as shown in FIG. 6, as they show up predominantly in first row 430, another yarn, such as a fourth yarn 442, could show up in row 440, possibly along with a fifth yarn 444. One could understand in row 430 as well as row 440 that the third yarn 426, if utilized, could be hidden from view due to randomized twisting. The next yarn 426 which could now be a sixth yarn 446 shown in row 442 can be seen as reference to FIG. 9. Still other rows such as row 448 may be provided with a single yarn as a seventh yarn 450 or otherwise.

As one can see with reference to FIG. 10, a lot of different yarns could be tufted with the various needles 412,418 and others across the carpet 410. Various elevations could also be tufted as will be explained below. More than three yarns 422-426 could be provided to needle 412 for tufting, such as four, five, or even more for some embodiments.

Accordingly, one may see in many embodiments a twist pattern could be random of the first, second and/or third yarns 422,424,426 as well as other combinations of any other yarns shown herein. Furthermore, although three yarns 422-425 are shown twisted, there certainly could be two yarns provided together from needle 412 and more than three yarns as would be understood by those of ordinary skill in the art as directed through each of the various needles 412,418. Differing deniers can add to this effect.

The carpet of FIG. 10 is relatively impervious to bleach if not completely impervious to bleach since the yarns 422-426 are solution dyed yarns which are not subject to being dyed after tufting. Instead, these yarns are manufactured with a particular color as opposed to being designed to be able to accept color through a dyeing process. In addition to being impervious to bleach, they are also impervious to dyes and/or stains or at least substantially impervious thereto as would be understood by those of ordinary skill in the art.

In addition to the linear striation along a single height as is possibly shown in FIG. 7 as well as FIG. 10, it is also possible to elevate one tuft relative to another as is shown in FIG. 8 with a first tuft 452 tufted to a first height and the second tuft 454 tufted to a second height and then a third tuft 456 being tufted back to the first height 460 with the second height 458 being illustrated as well. By having elevations in height, one can create different patterns.

One can anticipate that the relative twisting of yarns could be relative loosely which is defined as less than one complete twist per six inches and in many embodiments less than one twist per twelve inches or one twist for 24 inches and that the twist rate will change over length, preferably constantly changing for many embodiments as described above and herein.

In addition to manufacturing carpet 410 according to the present preferred embodiment of the present invention, one can also manufacture carpet tile by cutting the carpet 410 into predetermined shapes which are normally rectangularly (i.e., square) after tufting. By having the striated look as is shown in FIGS. 2 and 5, the ability to provide carpet tiles is enhanced in that there is less likely to be a noticeable difference at the intersections of tiles.

It may be possible to provide extruded yarn calculated to be striated as it is provided from the spinnerets as a single yarn. When manufacturing these yarns, it may be that different filaments may be combined together so that the individual yarn strands provides the appearance of being striated along its length. However, these techniques would relate to a single yarn and not multiple yarns as directed through a single needle.

FIGS. 13-15 show various ways of combining yarns 14,16,18,15 and 17 together at or before the eye 20 of the needle 12. FIG. 13 shows first and second yarns 14,16 twisted together as a first pair 21 joining third yarn 18, and possibly fourth and fifth yarns 15, 17 as well. FIG. 14 shows third and fourth yarns 18,15 twisted into a second pair 23 to join at the eye 20 of the needle 12, possibly together with optional fifth yarn 17. FIG. 15 shows somewhat of a trio 25 of yarns 14,16,18 which could be three with a predetermined twist rate, or even first and second yarns 14, 16 first twisted together and then third yarn 18 twisted about the first pair 21 to provide the trio 25. Similarly, trios 25 could be made of third, fourth and fifth yarns 18,15,17 as would be understood by those of ordinary skill in the art in an identical, similar or different manner. Meanwhile optional fourth and fifth yarns 15,17 are shown being fed to the eye 20 of the needle 12. The different way that the yarns combine at the needle 12 can affect how they are viewed as tufts such as 452, 454, 456 extending from backing 432 once tufted to make the carpet 32. Remember, not only can the yarns 14,16,18,15,17 have differing twist rates, but also be made up of different deniers of yarns, and/or be solution dyed heat set yarn as would be understood by those of ordinary skill in the art. Twist rates can be achieved through twisting, cabling, feeding together, piggybacking, feeding from different beams or cones, etc. Multiple yarns 14,16 and others may be fed from a common beam so as to rotate from a single beam about a single axis to which both (or more) yarns 14,16 are wound about, and unwind about the single axis to be fed to one or more needles (such as a single eye of a needle, or otherwise).

Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims. 

Having thus set forth the nature of the invention, what is claimed herein is:
 1. A method of manufacturing carpet comprising: directing first and second distinct yarns to be adjacently tufted beside one another on a tufting machine as directed from a common beam; and tufting carpet; wherein the first and second distinct yarns have a denier differential with the first yarn having a denier at least 50 higher than the second yarn.
 2. The method of claim 1 wherein the first yarn has a denier at least 100 higher than the second yarn, and the directing step further comprises directing the first and second distinct yarns to a single eye of a needle to then perform the tufting carpet step.
 3. The method of claim 1 wherein the first yarn has a denier at least 150 higher than the second yarn.
 4. The method of claim 1 wherein the first yarn has a denier at least 200 higher than the second yarn.
 5. The method of claim 1 wherein the first yarn has a denier at least 250 higher than the second yarn.
 6. The method of claim 1 wherein the first yarn has a denier at least 300 higher than the second yarn.
 7. The method of claim 1 wherein the first denier is above 1000 and the second denier is below
 1000. 8. The method of claim 2 wherein the step of directing the first and second distinct yarns further comprises directing a third yarn from the common beam to the single eye of the needle.
 9. The method of claim 8 wherein the third yarn has a different denier than the first and second yarns.
 10. A method of manufacturing carpet comprising: directing first and second distinct yarns to single eye of a needle of a tufting machine; and tufting carpet using the single needle; wherein the first and second distinct yarns have a denier differential with the first yarn having a denier at least 120% of the second yarn.
 11. The method of claim 10 wherein the first yarn has a denier at least 125% of the second yarn, and the directing step further comprises directing the first and second distinct yarns from a common beam.
 12. The method of claim 10 wherein the first yarn has a denier at least 133% of the second yarn.
 13. The method of claim 10 wherein the first yarn has a denier at least 150% of the second yarn.
 14. The method of claim 10 wherein the first denier is above 1000 and the second denier is below
 1000. 15. The method of claim 10 wherein the first denier is above 1000 and the second denier is below
 1000. 16. The method of claim 10 wherein the step of directing the first and second distinct yarns further comprises directing a third yarn from the common beam to the single eye of the needle.
 17. A method of manufacturing carpet comprising: directing first and second distinct yarns to single eye of a needle of a tufting machine from a common beam; and tufting carpet using the single needle; wherein the first distinct yarn has a denier less than 1000 and the second distinct yarn has a denier over
 1000. 18. The method of claim 17 wherein the first and second distinct yarns have a denier differential with the first yarn having a denier at least 50 higher than the second yarn.
 19. The method of claim 17 wherein the first and second distinct yarns have a denier differential with the first yarn having a denier at least 120% of the second yarn.
 20. The method of claim 17 wherein the step of directing the first and second distinct yarns further comprises directing a third yarn from the common beam to the single eye of the needle. 